Self-Hanging Notched Ceiling Tile

ABSTRACT

A ceiling tile with two pairs of outer straight opposing edges for a suspended ceiling having a grid with an opening with two pairs of near-horizontal opposing flanges on which the outer edges of the tile are supported. Two opposing notches on one of the pair of edges receive and rest upon one of the pairs of opposing flanges to vertically hang the ceiling tile.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Continuation-in-part of Design patent application Ser. Nos. 29/394,417 and 29/394,422 both filed on Jun. 16, 2011 respectively for Self-Hanging Tegular Notched Ceiling Tile and Self-Hanging Square Edge Notched Ceiling Tile.

BACKGROUND OF THE INVENTION

This invention relates to suspended ceiling systems and more particularly to ceiling tiles/panels that typically lay-in an exposed suspended ceiling grid or lattice.

The grid profile can vary from the standard inverted-T design in various exposed face widths, to more complicated bolt-slot (‘reveal’) and channel profile (‘bandraster’) profiles. Any grid profile with (most likely horizontal, or near-horizontal) flanges on which the outer edges of lay-in tiles/panels are supported will accommodate the use of this invention.

Above the array in the plenum are located electrical and computer wiring, ventilation equipment and duct work, lighting systems, sound systems and an array of other mechanical systems. Suspended ceilings have the advantage of hiding all of these mechanical and electrical components.

Typical appropriate, light-weight tile/panel compositions include; but are not limited to, vitreous fibers, natural organic fibers, plastic resins, solid metals and metal alloys, perforated metals and metal alloys, expanded metals and metal alloys, woven and welded wire fabrics, cast minerals, gypsum and all the possible mixtures, combinations, and laminations of the above materials.

Once the grid profile has been hung from the structural ceiling by metal straps, threaded rods or wires, the tiles are removed from their group packaging and one by one are lifted through a rectangular grid opening at an angle and then are lowered substantially flat so that their edges catch and lay on the inwardly extending flanges of the grid.

From time to time maintenance work must be performed above the suspended ceiling within the plenum. When a maintenance person needs to access the plenum area above a suspended ceiling, either the lay-in ceiling tiles/panels are pushed up into the ceiling and laid on top of another area of ceiling grid, or the tiles/panels must be removed from the ceiling and brought down to the lift platform, scaffolding, floor, tabletop, or other surface for temporary storage. In either case, the ceiling tiles/panels can be easily damaged in the process of removal. Tiles that are pushed into the ceiling plenum can be marred or scratched by being slid across the grid, or across light fixtures, smoke alarms, and other mechanical or electrical items attached to other tiles. Plus when the removed tile is placed on top of other panels and the previously listed items, the lower aesthetic surface of the removed tile may become soiled by the dust and dirt that collects on the upper surface of these other suspended ceiling components. Also, the edges of tiles can become damaged by accidentally being slid into grid hanger wires, threaded suspension rods, or other sharp objects within the plenum.

Tiles that are removed from the ceiling and brought down to a lower surface for temporary storage can be damaged during handling, both during removal and re-installation. The tiles can be scraped or scratched when passing through the grid opening. They can be bumped against ladders or lifts, and they can be accidentally dropped during this removal and transfer process. Once placed in a temporary storage location, the tiles are subject to multiple sources of potential damage: personnel and machinery could run into them; liquids could be spilled, dripped on them, or flood the surface on which they are placed. The surface on which the tiles are placed could be dirty and/or oily and could transfer directly to the aesthetic, visible surfaces of the tiles or could be transferred during subsequent handling. If placed in an upright position, on edge, the tiles could fall over or slide down onto the floor and be walked on or run over by vehicles.

Also, the process of removing tiles temporarily and placing them somewhere in the area below the ceiling, and then re-installing these same panels sometime later requires a great deal of time to accomplish.

SUMMARY OF THE INVENTION

A ceiling tile with two pairs of outer straight opposing edges for a suspended ceiling having a grid with an opening with two pairs of near-horizontal opposing flanges on which the outer edges of the tile are supported. Two opposing notches on one of the pair of edges receive and rest upon one of the pairs of opposing flanges to vertically hang the ceiling tile.

A principal object, advantage and feature of the self-hanging notched ceiling tile is that the notch is designed to support the ceiling tile in a vertical orientation on the horizontal flanges of the grid profile when the ceiling tile/panel is relocated from its normal lay-in horizontal location in order to gain access to the plenum space above the suspended ceiling.

Another object and advantage of the notched tile is that multiples of the notched tile maybe deliberately hung in a vertical orientation from the grid in a ‘baffle’ arrangement with an ‘open-plenum’ ceiling design for absorption of undesirable room noises to create a more quite environment.

Another object and advantage of the notched tile is that the feature can be employed in any composition of ceiling tile that is strong enough that the tile can be supported only along its' outer edges (by notches) without damage or failure because the tile is stiff enough that the panel will not excessively deflect or slip off the flange on the grid.

Another object and advantage of the notched tile is that the pair of notches are located close to the upper edge of the vertically hung tile. By this arrangement, the upper portion of the tile does not extend beyond the upper limits of grid profile into the plenum space.

Another object and advantage of the notched tile, which can easily be hung from the ceiling grid, is that it will greatly reduce the potential for overall damage and soiling of the visible aesthetic surface of the notched tile.

Another object and advantage of the notched tile is the significant time savings in the reduced time involved to temporarily hang the tiles from the grid. This hanging time is much less than removing them to a temporary storage location below the ceiling and to place the tiles away from the actual working area. When hanging the tile by its notches, the aesthetic surface is faced away from the worker.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a suspended ceiling with the notched ceiling tile of the present invention;

FIG. 2 is another perspective view of a suspended ceiling with the notched ceiling tile of the present invention;

FIG. 3 is another perspective view of a suspended ceiling with the notched ceiling tile of the present invention;

FIG. 4 is an enlarge perspective view of the suspended ceiling with the notched ceiling tile of the present invention as circled in FIG. 3;

FIG. 5 is front elevational view of a suspended ceiling with the notched ceiling tile of the present invention;

FIG. 6 is an enlarge front elevational view of the suspended ceiling with the notched ceiling tile of the present invention as circled in FIG. 5;

FIG. 7 is a top plan view of a notched square edge ceiling tile broken away;

FIG. 8 is another top plan view of a notched square edge ceiling tile;

FIG. 9 is another top plan view of a notched tegular ceiling tile;

FIG. 10 is another top plan view of a notched square edge ceiling tile;

FIG. 11 is a perspective view of a suspended ceiling with the notched ceiling tile of the present invention hung in a vertical sound baffling arrangement; and

FIG. 12 is another perspective view of the sound baffling arrangement of FIG. 13.

DETAILED SPECIFICATION

Referring to FIGS. 1 through 6, the self-hanging notched ceiling tile or panel 20 of the present invention may be appreciated. The Ceiling tile 20 works with a suspended ceiling 2. Above suspended ceiling tile 20 is the plenum where electrical, mechanical and air handling equipment is located and to generally be hidden by the suspended ceiling 2. The ceiling is suspended by hangers 6 which support and hold the ceiling grid or lattice 8 generally in a horizontal fashion. The grid 8 is an array of rectangles that have openings 10 therein for placement of the ceiling tiles 20. The lowermost elements of the grid 8 are generally rails that are profiled as inverted-Ts 12 with a flange 14 upon which the ceiling tile 20 rests thus hiding the plenum from view from below thereby rendering an aesthetic view of the ceiling.

The ceiling tile 20 typically is square edged or tegular with a lowered plane rendering a sculptured appearance. The ceiling tile 20 has a first pair of outer straight opposing edges 22 and a second pair of outer straight opposing edges 24. These edges 22 and 24 rest upon the flanges 14 of the grid 8 to support the ceiling panels 20 in an installed fashion. The ceiling panels have a lower aesthetic face or surface 26 and an upper plenum face or surface 28 that is generally unfinished. However, both faces 26 and 28 may be finished when the ceiling tiles 20 are desired to be suspended vertically to create a more open plenum 4 and to create sound baffles.

As more clearly seen in FIGS. 4 and 6, the notch 32 has a first wall 34 that is substantially 90° from the edge 22 or 24 that is bearing the notch 32. A second wall 36 is also substantially 90° from the first wall 34. This arrangement assures that ceiling tile 20 securely rests upon flange 14 when a maintenance worker desires to access the plenum 4. A third wall 38 is oblique from the second wall 36 and typically greater than 90° to assist in guiding the ceiling tile 20 into its vertically hanging condition. Notches 20 are suitably formed in either or both edges 22 and 24 generally close and parallel from the adjoining edges 22 or 24. By this arrangement, tiles 20 do not protrude into the plenum as to interfere with work being performed by the maintenance worker as the tile is simply hung from flanges 14 at notches 32.

The Notch 20 feature suitably may be created by employing a ‘hauncher’, which is a machine normally used in the woodworking industry to produce complicated two-dimensional profiles (shaped cuts) along the edges of boards or panels. The hauncher employs a rotating tool with the shape of the feature profile much like a large router bit. The rotating tool can move through the stationary tiles 20, or the tiles 20 can move past the stationary rotating tool. Haunchers are available from Progressive Systems, Inc. of Anoka, Minn. The notch 20 could also be fabricated by various methods including; but not limited to, punching, jig-sawing, routing, water jet cutting, laser cutting or with a hand punch tool. The specific fabrication method of the notch 20 is often based on the mechanical properties of the tile 20 composition being cut.

Installation of the ceiling tiles 20 of the present invention is standard in the industry. After the grid 8 has be securely suspended by hangers 6, the installer removes tiles 20 from their packaging and lifts each tile 20 through an opening 10 at an angle as to clear and not touch the grid flanges 14. The tile 20 is lowered substantially horizontally so that edges 22 and 24 come to rest upon flanges 14 of the grid 8.

FIGS. 3 through 6 illustrate the vertically hanging of ceiling tiles 20 for easy, safe and timely access to the plenum 4 for maintenance. FIGS. 3 and 4 show tegular tiles 20 with notch 32 having a first wall 34, a second wall 36 and third wall 38. The maintenance worker simply lifts the desired tile(s) 20, twists or rotates the tile 20 and lowers it down into grid opening 10 and hangs the tile 20 by aligning notches 32 with flanges 14. Ceiling tiles 20 may have two opposing notches 32 or may have two pair of opposing notches 32 as is shown. After the work is completed in the plenum 4, the worker simply lifts ceiling tile 20 off flanges 14, rotates and lifts the tile 20 up past opening 10 and then horizontally lowers the tile 20 into horizontal position so that edges 22 and 24 rest upon flanges 14.

Based on the required size and location of the notches 32 on the particular tile 20 and the mechanical properties and composition of the tile 20, the notches 20 may require different shapes as shown in FIGS. 7 through 10. FIG. 7 shows a square edge tile 40 having its notches 42 each having a first wall 44 and a second wall 46 with reinforcement 48. FIG. 8 shows a square edge tile 52 having its notches 54 each having a first wall 56 and a second wall 58 with a plastic reinforcement 60. FIG. 9 shows a tegular tile 64 having its notches 66 each having a first wall 68, a second wall 70 and a third wall 72. FIG. 10 shows a square edge tile 76 having its notches 78 each having a first wall 80, a second wall 82 and a third wall 84.

The physical design of the notch is to be shaped such that when the tile 20 is hanging vertically between two parallel flange sections 14 of ceiling grid 8, the upper notch wall 34, closest to the upper edge of the tile, is shaped to conform to the upper surface of the grid flange 14 which the notch rests upon. For most cases this upper notch wall 34 will be horizontal; however, special grid profiles may require other shapes.

Again, mechanical properties and composition of the tile 40, may require the notches 42 to have some reinforcement 48. Possible reinforcements 48 in the notch 40 might include; but are not limited to, extra-heavy coatings of paint; coatings of epoxy or other liquids that harden into strong, tough surfaces; flat adhesive liner sheets (‘patches’) on the rear, unexposed surface of the tile 40 in the area surrounding the notch 42. The reinforcement liner material 48 could be paperboard, plastic, or metal sheets; rods, pins, or small bars of metal or plastic driven into the edge material of the tile 40 just above the notch 42; three-dimensional notch inserts/liners that fit into the notch and provide a strong, solid surface. These inserts/liners 48 could be formed, molded, or cast, they could be metal or plastic, the insert 48 could be held in place with adhesive or mechanical barbs. The inner notch wall 46 must be vertical and long enough to provide some clearance for ease of installation when hanging the tile 40 vertically. The distance between the vertical walls 46 of each side-to-side pair of notches 42 must be precisely maintained to minimize the visibility of the notches 42 when the tile 40 is installed in its normal lay-in position on the grid flanges 14. The optional notch third wall below the vertical wall 46 can be straight or curved as they connect back to the outer vertical edge of the tile 40. A rectangular notch is the simplest shape; however custom notches might be required for special grid profiles or to aid installation when the tile/panel is being hung vertically.

FIGS. 11 and 12 show the sound baffling arrangement. Self-hanging ceiling notched square edge ceiling tiles 20 are intentionally vertically hung to give a somewhat open plenum look when looking vertically upward. However from looking at an angle, the plenum is not visible and the tiles 20 assist in sound abatement.

The above embodiments are for illustrative purposes only. Various other embodiments of the present invention may be contemplated. The true scope of the present invention is described in the following claims. 

1. A ceiling tile with two pairs of outer straight opposing edges for a suspended ceiling having a grid with an opening with two pairs of near-horizontal opposing flanges on which the outer edges of the tile are supported, comprising: a) two opposing notches on one of the pair of edges that will receive and rest upon one of the pairs of opposing flanges to vertically hang the ceiling tile.
 2. The ceiling tile of claim 1, wherein the opposing notches are each substantially equal distant from the other pair of opposing edges.
 3. The ceiling tile of claim 1, wherein the opposing notches are each close to the other pair of opposing edges.
 4. The ceiling tile of claim 1, wherein the opposing notches each have a wall that is substantially 90° from the one pair of edges for hanging on the opposing flanges.
 5. The ceiling tile of claim 1, wherein the opposing notches each have a least three adjacent walls with the first wall being substantially 90° from the one pair of edges for hanging on the opposing flanges, the second adjacent wall being 90° from the first wall and the third wall being oblique to the second wall.
 6. The ceiling tile of claim 5, wherein the third wall is greater than 90° from the adjacent second wall.
 7. The ceiling tile of claim 1, wherein the opposing notches each have at least two adjacent walls with the first wall being substantially 90° from the one pair of edges for hanging on the opposing flanges and the second adjacent wall being oblique from the first.
 8. The ceiling tile of claim 1, wherein the opposing notches each have a tough reinforcement chosen from a group comprising an extra-heavy coating of paint; a coating of epoxy, a flat adhesive liner sheet, a paperboard, a plastic, or metal sheet; or a tough three-dimensional notch insert, all providing a strong, solid surface that will not easily abrade by contact with a flange.
 9. The ceiling tile of claim 1, wherein the tile comprises a composition chosen from a group comprising vitreous fibers, natural organic fibers, plastic resins, solid metals and metal alloys, perforated metals and metal alloys, expanded metals and metal alloys, woven and welded wire fabrics, or cast minerals, and all the possible combinations and laminations of these compositions.
 10. A ceiling tile with two pairs of outer straight opposing edges for a suspended ceiling having a grid with an opening with two pairs of near-horizontal opposing flanges on which the outer edges of the tile are supported, comprising: a) two opposing notches on one of the pair of edges that will receive and rest upon one of the pairs of opposing flanges to vertically hang the ceiling tile wherein the opposing notches are each substantially equal distant from and close to the other pair of opposing edges.
 11. The ceiling tile of claim 10, wherein the opposing notches each have a wall that is substantially 90° from the one pair of edges for hanging on the opposing flanges.
 12. The ceiling tile of claim 10, wherein the opposing notches each have a least three adjacent walls with the first wall being substantially 90° from the one pair of edges for hanging on the opposing flanges, the second adjacent wall being 90° from the first wall and the third wall being oblique to the second wall.
 13. The ceiling tile of claim 12, wherein the third wall is greater than 90° from the adjacent second wall.
 14. The ceiling tile of claim 10, wherein the opposing notches each have at least two adjacent walls with the first wall being substantially 90° from the one pair of edges for hanging on the opposing flanges and the second adjacent wall being oblique from the first.
 15. The ceiling tile of claim 10, wherein the opposing notches each have a tough reinforcement chosen from a group comprising an extra-heavy coating of paint; a coating of epoxy, a flat adhesive liner sheet, a paperboard, a plastic, or metal sheet; or a tough three-dimensional notch insert, all providing a strong, solid surface that will not easily abrade by contact with a flange.
 16. The ceiling tile of claim 10, wherein the tile comprises a composition chosen from a group comprising vitreous fibers, natural organic fibers, plastic resins, solid metals and metal alloys, perforated metals and metal alloys, expanded metals and metal alloys, woven and welded wire fabrics, or cast minerals, and all the possible combinations and laminations of these compositions.
 17. A ceiling tile with two pairs of outer straight opposing edges for a suspended ceiling having a grid with an opening with two pairs of near-horizontal opposing flanges on which the outer edges of the tile are supported, comprising: a) two opposing notches on one of the pair of edges that will receive and rest upon one of the pairs of opposing flanges wherein the opposing notches are each substantially equal distant from and close to the other pair of opposing edges. b) a wall in the notch that is substantially 90° from the one pair of edges for vertically hanging the ceiling tile by the notch on the opposing flanges.
 18. The ceiling tile of claim 17, further comprising, another adjacent wall being oblique to the second wall.
 19. The ceiling tile of claim 17, wherein the opposing notches each have at least two adjacent walls with the first wall being substantially 90° from the one pair of edges for hanging on the opposing flanges and the second wall being oblique from the first.
 20. The ceiling tile of claim 17, wherein the opposing notches each have a tough reinforcement chosen from a group comprising an extra-heavy coating of paint; a coating of epoxy a flat adhesive liner sheet, a paperboard, a plastic, or metal sheet; or a tough three-dimensional notch insert, all providing a strong, solid surface that will not easily abrade by contact with a flange.
 21. The ceiling tile of claim 17, wherein the tile comprises a composition chosen from a group comprising vitreous fibers, natural organic fibers, plastic resins, solid metals and metal alloys, perforated metals and metal alloys, expanded metals and metal alloys, woven and welded wire fabrics, or cast minerals, and all the possible combinations and laminations of these compositions. 